2007 Ski-Doo GSX, GTX, MX Z, Summit Snowmobile Factory Service Manual (P/N MMR2007-002)

This 2007 BRP shop manual covers the listed Ski-Doo REV Series GSX, GTX, MX Z, and SUMMIT snowmobiles, with separate repair procedures for fan-cooled and liquid-cooled Rotax engines.

• Engine repair: Engine removal, top-end and bottom-end disassembly, crankshaft bearing replacement, piston inspection, RAVE valve service, and engine leak testing.

• Fuel and lubrication: VM/TM carburetor service, fuel-pump testing, DPM diagnosis, oil-injection pump adjustment, and Semi-Direct Injection (SDI) repairs.

• Engine management: Power TEK and SDI closed-throttle resets, ECM replacement, sensor testing, and B.U.D.S. fault diagnosis.

• Drive systems and brakes: Bombardier Lite and TRA III/TRA VII clutch overhaul, pulley alignment, chaincase service, countershaft repairs, and hydraulic brake work.

• Suspension and steering: Front suspension, SC and SC-4 rear assemblies, HPG shock rebuilding, track adjustment, and ski alignment.

• Electrical systems: Ignition, charging, and starting tests, Digitally Encoded Security System (DESS) key programming, Rotax Electronic Reverse (RER) diagnosis, and connector service.

• Maintenance and bodywork: Scheduled inspections, seasonal storage and preseason preparation, body-panel replacement, and frame-component removal and installation.

Written for snowmobile technicians already familiar with BRP service procedures, this manual assumes access to the required hand tools and special service tools.

Engine and Cooling Repair

Separate top-end and bottom-end sections cover the 552, 593, 793, and 797 engine families. Procedures extend to crankcase separation, crankshaft inspection, piston and reed-valve checks, RAVE valve adjustment, and combustion-chamber measurement.

Cooling coverage distinguishes axial-fan service from liquid-cooling-system leak tests, thermostat inspection, and radiator replacement. Exhaust-system procedures address the tuned pipe, muffler, and exhaust gas temperature sensor.

Water/oil pump seals: The liquid-cooled engine sections describe shaft and seal replacement, including ceramic seal installer P/N 529 036 014. They identify the risk of damaging the ceramic seal, oil seal, or bearing through incorrect installation force.

Fuel Delivery and Electronic Diagnosis

The 600 HO SDI fuel delivery diagnostic flowchart combines pump-operation checks with pressure and leakage diagnosis. This helps distinguish electrical supply problems from regulator, injector, or pump check-valve faults before replacing components.

Electronic setup: B.U.D.S. instructions cover MPI and MPI-2 connections, closed-throttle resets, and ECM replacement requirements. EMS fault-code tables identify warning signals, while supplemental notes explain why P0336 can result from mechanical overspeed rather than an engine-management fault.

The Power TEK input/output diagram and SDI engine-connector pinout connect system operation with the documented sensor and circuit tests.

Clutch, Suspension, and Chassis Service

Clutch procedures address sheaves, bushings, rollers, and calibration, with W, X, and Z pulley-alignment references and clutch spring compressor P/N 529 036 012. The TRA section explains how impact-tool use can damage the pulley and alter its calibration.

Rear-suspension exploded views identify rail, idler-wheel, and arm assemblies. HPG T/A and racing clicker shock coverage extends to shim stacks, floating-piston positioning, bleeding, and nitrogen charging, supported by model-specific calibration charts.

Maintenance intervals cover drive belts, chaincase oil, and suspension lubrication. General torque tables address M4–M14 fasteners in grades 5.8 through 12.9, alongside component-specific tightening data and wear limits.

Snowmobile service involves rotating drive components and pressurized systems; use the proper tools, protective gear, and a safe workspace.

Electrical References and Wiring Coverage

Ignition-system testing sequences, trigger-coil resistance references, and lights/accessories power-distribution diagrams support electrical diagnosis. Connector procedures cover terminal removal, installation, and repair.

The final wiring section contains a legend and three supplementary circuit sheets: REV 600 HO SDI, REV XRS 800 HO Power TEK, and REV XRS 600 HO SDI.

Main wiring diagrams: The separate main diagrams referenced for the printed manual’s back-cover pocket are not included in this PDF.

Examples of Engine Leak and SDI Fuel-Pressure Specifications

These examples show a small selection of the manual’s diagnostic specifications.

Engine leak verification specifies a maximum test pressure of 34 kPa (5 PSI) and a three-minute holding period.

For 600 HO SDI models, the fuel-pump outlet specification is 400 kPa (58 PSI), with a fully charged battery. The manual specifies this pressure during START/RER pump activation and with the engine cranking or running.

Bookmarks, Diagram Detail, and PDF Contents

Search and section navigation: PDF text search is unavailable. Embedded bookmarks navigate the main sections, although three engine sub-bookmarks have misleading labels. Small labels on the supplementary wiring sheets are legible when enlarged.

One printable 680-page PDF in English: 22 introductory pages, 655 pages covering the main manual sections, and three supplementary wiring sheets. The total already includes 36 blank pages.